U.S. patent application number 13/149001 was filed with the patent office on 2012-10-04 for fuel pump module including a jet pump having multiple tubes.
This patent application is currently assigned to DENSO CORPORATION. Invention is credited to Patrick Powell, Kishore Tammineedi.
Application Number | 20120247590 13/149001 |
Document ID | / |
Family ID | 46925660 |
Filed Date | 2012-10-04 |
United States Patent
Application |
20120247590 |
Kind Code |
A1 |
Powell; Patrick ; et
al. |
October 4, 2012 |
FUEL PUMP MODULE INCLUDING A JET PUMP HAVING MULTIPLE TUBES
Abstract
A fuel pump module includes a reservoir and a jet pump. The
reservoir includes first and second prime sockets and the jet pump
includes a first tube defining a first nozzle and a second tube
defining a second nozzle. The first tube has a lower end disposed
in the first prime socket and an upper end configured to engage a
first line routed to a first position outside of the reservoir in a
fuel tank. The second tube has a lower end disposed in the second
prime socket and an upper end configured to engage a second line
routed to a second position outside of the reservoir in the fuel
tank.
Inventors: |
Powell; Patrick; (Farmington
Hills, MI) ; Tammineedi; Kishore; (Farmington Hills,
MI) |
Assignee: |
DENSO CORPORATION
Kariya-Shi
MI
DENSO INTERNATIONAL AMERICA, INC.
Southfield
|
Family ID: |
46925660 |
Appl. No.: |
13/149001 |
Filed: |
May 31, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61470179 |
Mar 31, 2011 |
|
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|
Current U.S.
Class: |
137/565.01 |
Current CPC
Class: |
F02M 37/106 20130101;
F02M 37/025 20130101; Y10T 137/85978 20150401; F02M 37/103
20130101 |
Class at
Publication: |
137/565.01 |
International
Class: |
F15D 1/00 20060101
F15D001/00 |
Claims
1. A fuel pump module, comprising: a reservoir including first and
second prime sockets; and a jet pump including a first tube
defining a first nozzle and a second tube defining a second nozzle,
the first tube having a lower end disposed in the first prime
socket and an upper end configured to engage a first line routed to
a first position outside of the reservoir in a fuel tank, the
second tube having a lower end disposed in the second prime socket
and an upper end configured to engage a second line routed to a
second position outside of the reservoir in the fuel tank.
2. The fuel pump module of claim 1, wherein the jet pump defines an
orifice that provides fluid communication between the first and
second tubes.
3. The fuel pump module of claim 2, further comprising an electric
pump operable to pump fuel from the reservoir, wherein the jet pump
includes a line connection in fluid communication with the orifice
and configured to engage a third line routed to a suction side of
the electric pump.
4. The fuel pump module of claim 3, wherein the first and second
tubes are oriented axially relative to the reservoir and the
orifice is oriented horizontally relative to the reservoir.
5. The fuel pump module of claim 1, wherein the jet pump includes
first and second bosses, the first boss extending horizontally from
the first tube, the second boss extending horizontally from the
second tube.
6. The fuel pump module of claim 5, wherein the first and second
bosses are offset from each other in a radial direction relative to
the reservoir.
7. The fuel pump module of claim 6, wherein: the reservoir includes
an outer wall, an inner wall spaced radially inward from the outer
wall, and through-hole sockets spaced around a perimeter of the
reservoir to define N zones between the inner and outer walls; the
jet pump is mounted to the reservoir in one of the N zones; and N
is an integer greater than one.
8. The fuel pump module of claim 7, wherein the reservoir includes
supports disposed in at least one of the N zones and configured to
support the jet pump.
9. The fuel pump module of claim 8, wherein the supports define
slots for receiving the first and second bosses.
10. The fuel pump module of claim 9, wherein the slots are offset
from each other in a radial direction relative to the reservoir to
retain the jet pump.
11. The fuel pump module of claim 1, further comprising a check
valve disposed at a lower end of the jet pump and configured to
selectively prevent fuel flow through the first and second tubes
from the first and second prime sockets.
12. The fuel pump module of claim 11, wherein the check valve
includes a first float selectively positioned at the lower end of
the first tube and a second float selectively positioned at the
lower end of the second tube.
13. The fuel pump module of claim 12, wherein the first and second
floats are adapted to engage the lower end of the jet pump to
create a seal and to move away from the lower end of the jet pump
to allow fuel to flow through the lower end of the jet pump in
response to pressure changes within the jet pump.
14. A fuel pump module, comprising: a reservoir configured to
contain fuel, the reservoir including an outer wall, an inner wall
spaced radially inward from the outer wall, through-hole sockets
spaced around a perimeter of the reservoir to define N zones
between the inner wall and the outer wall, and prime sockets
disposed in at least one of the N zones, wherein N is an integer
greater than one; and a jet pump including multiple tubes defining
multiple nozzles and having lower ends disposed in the prime
sockets and upper ends configured to engage lines routed to
different positions within a fuel tank outside of the
reservoir.
15. The fuel pump module of claim 14, further comprising an
electric pump operable to pump fuel from the reservoir, wherein the
jet pump includes a line connection in fluid communication with the
multiple tubes and configured to engage a feed line routed to a
suction side of the electric pump.
16. A jet pump, comprising: a first tube defining a first nozzle
and a first cylindrical passage; and a second tube defining a
second nozzle and a second cylindrical passage.
17. The jet pump of claim 16, wherein the first and second nozzles
converge from a lower end of the jet pump to an upper end of the
jet pump.
18. The jet pump of claim 16, further comprising an orifice
providing fluid communication between the first and second
tubes.
19. The jet pump of claim 18, wherein the orifice extends
horizontally and the orifice is disposed between the first nozzle
and the first cylindrical passage and between the second nozzle and
the second cylindrical passage.
20. The jet pump of claim 18, further comprising a line connection
in fluid communication with the orifice and configured to engage a
feed line routed to a suction side of an electric pump.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/470,179, filed on Mar. 31, 2011.
FIELD
[0002] The present disclosure relates to fuel pump modules, and
more particularly, to fuel pump modules including jet pumps having
multiple tubes.
BACKGROUND
[0003] This section provides background information related to the
present disclosure which is not necessarily prior art.
[0004] A fuel pump module typically includes a flange that mounts
to a top surface of a fuel tank, rods that couple a reservoir to
the flange, and springs around the rods that bias the reservoir
against a bottom surface of the fuel tank. Various components are
typically mounted to an outer wall of the reservoir, including a
main pump, an auxiliary pump, and a sender gauge. Typically, the
sender gauge is disposed outside of the reservoir and is oriented
vertically.
[0005] Conventionally, the number of sockets included in the flange
and the reservoir is equal to the number of rods coupling the
reservoir to the flange. In addition, the main pump, the auxiliary
pump, and the sender gauge can each only be mounted to the
reservoir in a single position. Due to packaging constraints, it
may be desirable to reposition the reservoir relative to the
flange. In addition, it may be desirable to reposition the main
pump, the auxiliary pump, and/or the sender gauge relative to the
reservoir. However, repositioning the reservoir or the components
mounted to the reservoir would require redesigning the fuel pump
module, which would drive engineering and tooling costs.
SUMMARY
[0006] This section provides a general summary of the disclosure,
and is not a comprehensive disclosure of its full scope or all of
its features.
[0007] A fuel pump module includes a reservoir and a jet pump. The
reservoir includes first and second prime sockets and the jet pump
includes a first tube defining a first nozzle and a second tube
defining a second nozzle. The first tube has a lower end disposed
in the first prime socket and an upper end configured to engage a
first line routed to a first position outside of the reservoir in a
fuel tank. The second tube has a lower end disposed in the second
prime socket and an upper end configured to engage a second line
routed to a second position outside of the reservoir in the fuel
tank.
[0008] The jet pump may define an orifice that provides fluid
communication between the first and second tubes.
[0009] The fuel pump module may further include an electric pump
operable to pump fuel from the reservoir. The jet pump may include
a line connection in fluid communication with the orifice and may
be configured to engage a third line routed to a suction side of
the electric pump.
[0010] The first and second tubes may be oriented axially relative
to the reservoir and the orifice may be oriented horizontally
relative to the reservoir.
[0011] The jet pump may include first and second bosses, the first
boss extending horizontally from the first tube, the second boss
extending horizontally from the second tube.
[0012] The first and second bosses may be offset from each other in
a radial direction relative to the reservoir.
[0013] The reservoir may include an outer wall, an inner wall
spaced radially inward from the outer wall, and through-hole
sockets spaced around a perimeter of the reservoir to define N
zones between the inner and outer walls, where N is an integer
greater than one. The jet pump may be mounted to the reservoir in
one of the N zones.
[0014] The reservoir may include supports disposed in at least one
of the N zones and configured to support the jet pump.
[0015] The supports may define slots for receiving the first and
second bosses.
[0016] The slots may be offset from each other in a radial
direction relative to the reservoir to retain the jet pump.
[0017] The fuel pump module may further include a check valve
disposed at a lower end of the jet pump and configured to
selectively prevent fuel flow through the first and second tubes
from the first and second prime sockets.
[0018] The check valve may include a first float selectively
positioned at the lower end of the first tube and a second float
selectively positioned at the lower end of the second tube.
[0019] The first and second floats may be adapted to engage the
lower end of the jet pump to create a seal and to move away from
the lower end of the jet pump to allow fuel to flow through the
lower end of the jet pump in response to pressure changes within
the jet pump.
[0020] The first tube may define the first nozzle and a first
cylindrical passage and the second tube may define the second
nozzle and a second cylindrical passage.
[0021] The first and second nozzles may converge from a lower end
of the jet pump to an upper end of the jet pump.
[0022] The orifice may extend horizontally and may be disposed
between the first nozzle and the first cylindrical passage and
between the second nozzle and the second cylindrical passage.
[0023] Further areas of applicability will become apparent from the
description provided herein. The description and specific examples
in this summary are intended for purposes of illustration only and
are not intended to limit the scope of the present disclosure.
DRAWINGS
[0024] The drawings described herein are for illustrative purposes
only of selected embodiments and not all possible implementations,
and are not intended to limit the scope of the present
disclosure.
[0025] FIG. 1 is a side view of a vehicle depicting a location of a
vehicle fuel system;
[0026] FIG. 2 is a side view of a vehicle fuel system depicting a
fuel pump module within the fuel tank;
[0027] FIG. 3 is a perspective view of a fuel tank depicting an
aperture for installation of a fuel pump module;
[0028] FIG. 4 is a perspective view of a fuel pump module depicting
components of the fuel pump module in a first position relative to
one another;
[0029] FIG. 5 is a top view of the fuel pump module of FIG. 4
depicting the components of the fuel pump module in the first
position relative to one another;
[0030] FIG. 6 is a perspective view of the fuel pump module of FIG.
1 depicting the components of the fuel pump module in a second
position relative to one another;
[0031] FIG. 7 is a top view of the fuel pump module of FIG. 4
depicting the components of the fuel pump module in the second
position relative to one another;
[0032] FIG. 8 is a perspective view of the fuel pump module of FIG.
4 depicting the components of the fuel pump module in a third
position relative to one another;
[0033] FIG. 9 is a top view of the fuel pump module of the FIG. 4
depicting the components of the fuel pump module in the third
position relative to one another;
[0034] FIG. 10 is an exploded view of the fuel pump module of FIG.
4 depicting the components of the fuel pump module;
[0035] FIG. 11 is a perspective view of a reservoir included in the
fuel pump module of FIG. 4 depicting an inner wall defining an
inner zone and an outer zone;
[0036] FIG. 12 is a top view of the reservoir of FIG. 11;
[0037] FIG. 13 is a perspective view of a pump and filter assembly
included in the fuel pump module of FIG. 4 depicting brackets for
attachment to the inner wall of the reservoir of FIG. 11;
[0038] FIG. 14 is a top view of the pump and filter assembly of
FIG. 13;
[0039] FIG. 15 is a perspective view of an auxiliary pump included
in the fuel pump module of FIG. 4;
[0040] FIG. 16 is a top view of the auxiliary pump of FIG. 15;
[0041] FIG. 17 is a section view of the auxiliary pump of FIG. 15
depicting a check valve in a closed position that prevents fuel
flow through the auxiliary pump;
[0042] FIG. 18 is a section view of the auxiliary pump of FIG. 15
depicting the check valve in an open position that allows fuel flow
through the auxiliary pump;
[0043] FIG. 19 is a side view of the fuel pump module of FIG. 4
depicting an auxiliary filter through which fuel flows before
reaching the auxiliary pump of FIG. 15;
[0044] FIG. 20 is a close up view of a portion of FIG. 19 within a
line 20;
[0045] FIG. 21 is a perspective view of a portion of the fuel pump
module of FIG. 4 depicting a lower end of a sender gauge mounted
within a reservoir;
[0046] FIG. 22 is a top view of the sender gauge of FIG. 21;
[0047] FIG. 23 is a perspective view a portion of the fuel pump
module of FIG. 4 depicting an upper end of the sender gauge of FIG.
21 mounted to the inner wall of the reservoir shown in FIG. 11;
[0048] FIG. 24 is a perspective view of a flange included in the
fuel pump module of FIG. 4 depicting sockets for receiving rods and
a hose included in the fuel pump module; and
[0049] FIG. 25 is a bottom view of the flange of FIG. 24.
[0050] Corresponding reference numerals indicate corresponding
parts throughout the several views of the drawings.
DETAILED DESCRIPTION
[0051] Example embodiments will now be described more fully with
reference to the accompanying drawings.
[0052] Although the terms first, second, third, etc. may be used
herein to describe various elements, components, regions, layers
and/or sections, these elements, components, regions, layers and/or
sections should not be limited by these terms. These terms may be
only used to distinguish one element, component, region, layer or
section from another region, layer or section. Terms such as
"first," "second," and other numerical terms when used herein do
not imply a sequence or order unless clearly indicated by the
context. Thus, a first element, component, region, layer or section
discussed below could be termed a second element, component,
region, layer or section without departing from the teachings of
the example embodiments.
[0053] Spatially relative terms, such as "inner," "outer,"
"beneath," "below," "lower," "above," "upper," "top," "bottom," and
the like, may be used herein for ease of description to describe
one element or feature's relationship to another element(s) or
feature(s) as illustrated in the figures. Spatially relative terms
may be intended to encompass different orientations of the device
in use or operation in addition to the orientation depicted in the
figures. For example, if the device in the figures is turned over,
elements described as "below" or "beneath" other elements or
features would then be oriented "above" the other elements or
features. Thus, the example term "below" can encompass both an
orientation of above and below. The device may be otherwise
oriented (rotated 90 degrees or at other orientations) and the
spatially relative descriptors used herein interpreted
accordingly.
[0054] Referring now to FIG. 1, a vehicle 10, such as an
automobile, includes an engine 12 and a fuel system 14. The fuel
system 14 includes a fuel supply line 16, a fuel tank 18, and a
fuel pump module 20. The fuel pump module 20 mounts within the fuel
tank 18 with a flange and is normally submerged in or surrounded by
varying amounts of liquid fuel within the fuel tank 18 when the
fuel tank 18 contains liquid fuel. A fuel pump within the fuel pump
module 20 pumps fuel to the engine 12 through the fuel supply line
16.
[0055] Referring now to FIG. 2, the fuel system 14 includes a fuel
rail 22 and fuel injectors 24. In a returnless fuel system, only
the fuel supply line 16 carries fuel between the fuel pump module
20 and the fuel rail 22. Once the fuel reaches the fuel rail 22,
also called a "common rail," as depicted in FIG. 2, the fuel passes
into the individual fuel injectors 24 before being sprayed or
injected into individual combustion chambers of the engine 12. The
fuel system 14 depicted in FIG. 2 has no fuel return line from the
fuel rail 22 to the fuel tank 18. However, the fuel system 14 may
be a return-type fuel system that includes a fuel return line (not
shown).
[0056] With continued reference to FIG. 2, and additional reference
to FIGS. 3 through 5, the fuel tank 18 has a mounting location 26,
a hole, about which is a mounting surface 28 on the top of the fuel
tank 18 for the fuel pump module 20. The fuel pump module 20 may be
lowered through the hole of the mounting location 26 on top of the
fuel tank 18 when installed. More specifically, a fuel pump module
flange 30 rests on the mounting surface 28 when the fuel pump
module 20 is in its installed position. The fuel tank 18 includes
retaining feature 32, such as a lip, that retains the flange 30 at
the mounting location 26 by, for example, engaging a tab 34 on the
flange 30.
[0057] Additionally, the fuel pump module 20 includes a generally
vertical cylindrical reservoir 36. Alternatively, the reservoir 36
may be oriented generally horizontally (not shown). An advantage of
a horizontal reservoir is that less fuel tank depth is necessary to
accommodate the reservoir. Alternatively, an advantage of a
vertical reservoir is that less horizontal space is necessary for
its installation and the reservoir itself may be firmly biased
against the bottom interior of the fuel tank. That is, generally a
vertical reservoir may have a smaller overall diameter than a
horizontal reservoir for the same vehicle application.
[0058] The fuel pump module 20 includes a main pump 38, which may
be an electric pump. The main pump 38 draws fuel from the reservoir
36 and through a main filter 40 and, in one example, through a
check valve 42 that may be disposed at or near the top of the main
pump 38. The check valve 42 opens in response to positive pressure
from within the main pump 38 to permit fuel to flow from the top of
the main pump 38 and into the fuel supply line 16 via a fuel supply
line port 44.
[0059] To successfully pump fuel as generally described above, the
fuel pump module 20 resides secured against a bottom interior
surface 46 of the fuel tank 18, as shown in FIG. 2. To maintain its
secured position against the bottom interior surface 46 of the fuel
tank 18, the fuel pump module 20 utilizes a first rod 48 and a
second rod 50. More specifically, the first rod 48 may be
surrounded by a first spring 52 and the second rod 50 may be
surrounded by a second spring 54. The first and second rods 48, 50
fix the fuel pump module 20 in a radial direction relative to the
fuel tank 18, and the springs 52, 54 bias the fuel pump module 20
against the bottom interior surface 46 of the fuel tank 18. Because
the rods 48, 50 function in the same manner, only the first rod 48
will be used to exemplify details of the disclosure.
[0060] A first end 56 of the first rod 48 may be secured to the
reservoir 36 so that the first rod 48 can slide vertically relative
to the reservoir 36. For example, the first end 56 may be passed
through part of the reservoir 36, such as one of a plurality of rod
sockets 60, and then the first end 56 may be crimped or a stop 58,
such as a c-clip, may be installed at the first end 56. The crimp
in the first end 56 or the stop 58 prevents the first end 56 from
backing out of the one of the rod sockets 60 in which the first end
56 is passed through. A second end 62 of the first rod 48 may be
secured to the flange 30 such as by a press or snap fit. For
example, the flange 30 may include a plurality of rod sockets 64,
and the second end 62 may be press fitted into one of the rod
sockets 64.
[0061] With continued reference to FIGS. 4 and 5, and additional
reference to FIGS. 6 through 9, the reservoir 36 may be
repositioned relative to the flange 30 without redesigning the
flange 30 or the reservoir 36. The reservoir 36 may be repositioned
by inserting the rods 48, 50 into different ones of the rod sockets
60 in the reservoir 36 and into different ones of the rod sockets
64 in the flange 30. For example, in FIGS. 4 and 5, the reservoir
36 is radially aligned with the flange 30. However, in FIGS. 6 and
7, the reservoir 36 has been rotated and radially offset by a first
distance relative to the flange 30. To accomplish this, the rods
48, 50 have been inserted into different ones of the rod sockets 64
in the flange 30.
[0062] In another example, in FIGS. 8 and 9, the reservoir 36 has
been rotated and radially offset by a second distance relative to
the flange 30. The second distance is greater than the first
distance. To accomplish this, the rods 48, 50 have been into
different ones of the rod sockets 60 in the reservoir 36 and into
different ones of the rod sockets 64 in the flange 30.
[0063] The reservoir 36 includes an outer wall 66, an inner wall 68
spaced radially inward from the outer wall 66, and a floor 70
connecting the outer and inner walls 66, 68. The reservoir 36 also
includes multiple sets of stanchions for supports 72 disposed
between the outer and inner walls 66, 68 and around the inner wall
68. The inner wall 68 divides the reservoir 36 into an inner zone
contained within the inner wall 68, and an outer zone between the
outer and inner walls 66, 68. The inner zone contains core
components such as the main pump 38 and the main filter 40. The
outer zone contains auxiliary components such as a sender gauge 74,
best shown in FIGS. 4 and 8, and an auxiliary pump 76, best shown
in FIG. 6. The auxiliary pump 76 may be an eductor-jet pump.
[0064] The sender gauge 74 includes arm brackets 78, an arm 80
inserted into one of the arm brackets 78, and a float 82 attached
to the arm 80. The float 82 raises and lowers in response to fuel
levels in the fuel tank 18 of FIG. 3. The sender gauge 74 detects
fuel levels in the fuel tank 18 based on movement of the arm
brackets 78, the arm 80, and the float 82. To satisfy packaging
requirements, the arm 80 may be inserted into either one of the arm
brackets 78. To illustrate this, the arm 80 and the float 82 are
shown in a first position represented by solid lines, and the arm
80 and the float 82 are shown in a second position represented by
dashed lines.
[0065] With specific reference to FIG. 6, the reservoir 36 includes
prime sockets 84 disposed between one of the sets of supports 72 on
the floor 70 of the reservoir 36, and the outer wall 66 of the
reservoir 36 defines a line socket 86. While the rod sockets 60 and
the line socket 86 may be through-hole sockets, the bottom end of
the prime sockets 84 may be closed by the floor 70 of the reservoir
36. The lower end of the auxiliary pump 76 is disposed in the prime
sockets 84, and the upper end of the auxiliary pump 76 is connected
to fuel lines routed to different positions outside of the
reservoir 36 within the fuel tank 18 of FIG. 3.
[0066] A pickup line 88 is routed from the upper end of the sender
gauge 74, through the line socket 86, and to a reservoir pickup or
auxiliary filter 90 located in a first position outside of the
reservoir 36 within the fuel tank 18. The outer wall 66 defines
grooves 92 extending axially from the rod sockets 60 and the line
socket 86 to the bottom of the reservoir 36. The grooves 92 may be
shaped and sized to accommodate the pickup line 88 such that the
outer surface of the pickup line 88 is generally flush with the
outer surface of the outer wall 66. A transfer line 94 is routed
from the upper end of the auxiliary pump 76 to a transfer port 96,
which may be connected to a fuel line routed to a second position
outside the reservoir 36 within the fuel tank 18. A feed line 98 is
routed from a suction side of the auxiliary pump 76 to the check
valve 42.
[0067] The main pump 38 is operable to prime the auxiliary pump 76.
The main pump 38 primes the auxiliary pump 76 by drawing fuel from
the prime sockets 84, through the auxiliary pump 76, and through
the feed line 98 to create a vacuum within the auxiliary pump 76.
In turn, the auxiliary pump 76 relies on the Venturi effect to draw
fuel from the first and second positions, through the auxiliary
filter 90 and the transfer port 96, through the pickup line 88 and
the transfer line 94, and into the reservoir 36.
[0068] Referring again to FIGS. 4 through 9, the rod sockets 60,
the line socket 86, and the grooves 92 may be equally spaced around
the perimeter of the reservoir 36 to divide the outer zone into a
plurality of equal zones. Although referred to as equal zones, the
equal zones may be equal in size, approximately equal in size, or
slightly different in size. The equal zones are defined by the
outer and inner walls 66, 68 and by adjacent ones of the rod
sockets 60, the line socket 86, and the grooves 92. One set of the
supports 72 is disposed in each of the equal zones. The supports 72
are configured to individually support and retain the sender gauge
74 and the auxiliary pump 76. Thus, the sender gauge 74 and the
auxiliary pump 76 may be mounted to the supports 72 within any one
of the equal zones.
[0069] However, if the rod sockets 60 and the line socket 86 have
different inner diameters, and the reservoir 36 includes only one
set of the prime sockets 84, then the auxiliary pump 76 may be
disposed in only one of the equal zones. Nonetheless, the sender
gauge 74 may be disposed in any one of the other equal zones.
Although the reservoir 36 includes four of the rod sockets 60 and
one of the line socket 86 cooperating to define five equal zones,
any number of rod and line sockets may be included to define any
number of equal zones.
[0070] In addition, the inner wall 68 includes retaining features
100, such as protrusions, configured to retain the core components,
including the main pump 38 and the main filter 40. For example, the
main pump 38 and the main filter 40 may be coupled to brackets 102,
which may be slid over the retaining features 100 to create a snap
fit that retains the main pump 38 and the main filter 40 to the
inner wall 68. Since the core components are attached to the inner
wall 68 rather than the outer wall 66, attaching the core
components to the reservoir 36 does not require brackets that
extend from the core components to the outer wall 66. Thus, the
sender gauge 74 and/or the auxiliary pump 76 may be disposed in any
one of the equal zones without interfering with such brackets.
[0071] In this regard, the fuel pump module 20 includes various
features providing flexibility to satisfy packaging constraints
within the fuel tank 18 of FIG. 3 without redesigning the fuel pump
module 20. These various features include the alternate positioning
of the reservoir 36 relative to the flange 30, the alternate
positioning of the arm 80, the equal zones containing the
universally configured supports 72, and the attachment of the core
components to the inner wall 68 rather than to the outer wall 66.
The flexibility provided by these various features may be utilized
to reconfigure the fuel pump module 20 rather than redesigning the
fuel pump module 20. In turn, the fuel pump module 20 may be
adapted to different vehicle applications at a reduced cost.
[0072] Referring now to FIG. 10, the main pump 38, the main filter
40, and the check valve 42 may be part of a pump and filter
assembly 104. The pump and filter assembly 104 may include a
housing 106 that houses the main pump 38 and the main filter 40,
and that couples the main pump 38, the main filter 40, and the
check valve 42 to the reservoir 36. The housing 106 includes the
brackets 102 that may be slid over the retaining features 100 to
create a snap fit that secures the main pump 38, the main filter
40, and the check valve 42 to the inner wall 68 of the reservoir
36. The main filter 40 and the check valve 42 may be inserted
through the upper end of the housing 106, and the main pump 38 may
be inserted through the lower end of the housing 106.
[0073] The upper end of the main pump 38 includes a connection 108
that connects the main pump 38 to the check valve 42. The lower end
of the main pump 38 is attached to a bracket 110 that clips onto
the outside surface of the housing 106 to secure the main pump 38
to the housing 106. The bracket 110 defines a regulator socket 112,
and a pressure regulator (not shown) may be inserted into the
regulator socket 112. The pressure regulator may be connected to
the fuel supply line port 44 via a line connection 114 coupled to
the bracket 110. The main pump 38 draws fuel from within the
reservoir 36 through the connection 108, and the main pump 38 pumps
fuel to the fuel supply line port 44 through the line connection
114. The pressure regulator may regulate the pressure of fuel
pumped from the main pump 38 to the fuel supply line port 44.
[0074] With continued reference to FIG. 10, and additional
reference to FIG. 12, a suction filter 116 (FIG. 10) is positioned
beneath the pump and filter assembly 104 and over an inlet 118
(FIG. 12) defined by the reservoir 36. The suction filter 116
filters fuel entering the reservoir 36 through the inlet 118. An
umbrella valve (not shown) may be positioned between the suction
filter 116 and the inlet 118. Further discussion of the suction
filter 116, the inlet 188, and the umbrella valve may be found in
commonly assigned U.S. patent application Ser. No. 13/100,671
(filed on May 4, 2011; Attorney Docket No. 4041A-000189), which is
incorporated by reference herein in its entirety.
[0075] With continued reference to FIG. 10, the sender gauge 74
includes a card mount 120 and a contact mount 122. A resistance
card 124 is fixed to the card mount 120 such that the length of the
resistance card 124 is oriented horizontally. The contact mount 122
includes the arm brackets 78, and the arm 80 is inserted into one
of the arm brackets 78. The arm 80 may extend through the contact
mount 122, and the portion of the arm 80 extending through the
contact mount 122 may form a resistance contact 126. The arm
brackets 78 rotate relative to the remainder of the contact mount
122 such that the arm 80 and the resistance contact 126 are
pivotally mounted to the contact mount 122.
[0076] The contact mount 122 is disposed at least partially within
one of the equal zones, the float 82 is disposed outside of the
reservoir 36, and the arm 80 extends from the contact mount 122,
over the outer wall 66 of the reservoir 36, to the float 82. The
card mount 120 is designed to avoid contact with the arm as the arm
80 pivots with the contact mount 122 relative to the card mount
120. In addition, the arm 80 is designed to avoid contact with the
reservoir 36 as the arm 80 pivots with the contact mount 122
relative to the card mount 120. Furthermore, the sender gauge 74 is
positioned to prevent contact between the arm 80 and the flange 30
when the arm 80 is completely raised.
[0077] In operation, the float 82 raises and lowers in response to
changes in the fuel levels of the fuel tank 18 of FIG. 3. As the
float 82 raises and lowers, the arm 80 and a portion of the contact
mount 122 including the arm brackets 78 rotate relative to the
remainder of the contact mount 122 and the card mount 120. In turn,
the resistance contact 126 travels through a radius along the
length of the resistance card 124. The sender gauge 74 detects
changes in fuel levels based on changes in the resistance between
the resistance card 124 and the resistance contact 126 as the
resistance contact 126 travels through the radius along the length
of the resistance card 124.
[0078] The resistance contact 126 travels in a first direction
along the length of the resistance card 124 when the arm 80 is
raised while fixed to a first one of the arm brackets 78. The
resistance contact 126 travels in a second direction along the
length of the resistance card 124 when the arm 80 is raised while
the arm 80 is fixed to a second one of the arm brackets 78. The
second direction is generally opposite from the first
direction.
[0079] Since the resistance card 124 is oriented horizontally, the
pivot point of the arm 80 may be positioned below the resistance
card 124 approximately midway along the length of the resistance
card. Also, the arm 80 may be assembled in either one of the two
positions shown in FIG. 10 while still allowing the resistance
contact 126 to sweep through the radius along the length of the
resistance card 124. In contrast, in sender gauges having a
resistance card oriented vertically, the pivot point is generally
located beside the resistance card approximately midway along the
length of the resistance card. Also, the arm may only be assembled
in a single position while still allowing the resistance contact to
travel through a radius along the length of the resistance
card.
[0080] When the arm 80 is switched from the primary position
represented in solid lines to the alternate position represented in
dashed lines, the resistance card 124 may be replaced with a second
resistance card (not shown) corresponding to the alternative
position. Alternatively, a controller (not shown) in communication
with the sender gauge 74 may have different settings for
interpreting the output of the sender gauge 74 depending upon the
positioning of the arm 80. In either case, the sender gauge 74
accurately indicates fuel levels in the fuel tank 18 of FIG. 3
regardless of the positioning of the arm 80.
[0081] With continued reference to FIG. 10, the auxiliary pump 76
includes a line connection 128 that connects to the feed line 98.
In addition, seals 130 and floats 132 may be disposed at or near
the lower end of the auxiliary pump 76 within the prime sockets 84
of the reservoir 36. The main pump 38 primes the auxiliary pump 76
by drawing fuel from the prime sockets 84, through the auxiliary
pump 76, and through the feed line 98. This creates a vacuum within
the auxiliary pump 76, enabling the auxiliary pump 76 to rely on
the Venturi effect to draw fuel through the pickup line 88 and the
transfer line 94 from various locations within the fuel tank 18 of
FIG. 3.
[0082] Fuel entering the auxiliary pump 76 forces the seals 130 and
the floats 132 downward into the prime sockets 84, allowing fuel to
exit the auxiliary pump 76 through the lower end of the auxiliary
pump 76. Otherwise, when fuel is not drawn into the auxiliary pump
76, the floats 132 force the seals 130 against the lower end of the
auxiliary pump 76 to create a seal. This seal prevents fuel within
the reservoir 36 from flowing through the lower end of the
auxiliary pump 76 and to locations outside of the reservoir 36. In
this regard, the seals 130 and the floats 132 form a check valve
that allows fuel flow into the reservoir 36 through the lower end
of the auxiliary pump 76 and prevents fuel flow out of the
reservoir 36 through the lower end of the auxiliary pump 76.
[0083] Referring now to FIGS. 11 and 12, with continued reference
to FIG. 10, the outer wall 66, the inner wall 68, the floor 70, the
supports 72, and the prime sockets 84 can be integrally formed or
separately formed and attached together. The floor 70 defines the
inlet 118, which is disposed radially inward relative to the inner
wall 68 at the center of the reservoir 36. Notwithstanding the
different configuration of the line socket 86 relative to the rod
socket 60 and the inclusion of only one set of the prime sockets
84, the reservoir 36 is symmetric around the longitudinal axis
extending through the center of the reservoir 36.
[0084] The flexibility of the fuel pump module 20 is provided in
part by the symmetry of the reservoir 36 and the positioning of the
inlet 118. The symmetry of the reservoir 36 enables mounting the
sender gauge 74 within any one of the equal zones disposed around
the perimeter of the reservoir other than the equal zone in which
the prime sockets 84 are disposed. The positioning of the inlet 118
enables repositioning the auxiliary pump 76 by rotating the
reservoir 36 about the longitudinal axis extending through the
center of the reservoir 36.
[0085] The inner wall 68 defines a plurality of vertical slots 134
that divide the inner wall 68 into a plurality of sections equal in
number to the number of equal zones. The sections each include a
first subsection 136 and a second subsection 138. The height of the
first subsections 136 is less than the height of the second
subsections 138. The outer surface of the second subsections 138
define the retaining features 100 that retain the pump and filter
assembly 104. Flanges 140 abut each end of the first and second
subsections 136, 138. The upper edges of the first subsections 136
and the flanges 140 cooperate to align, support, and retain the
sender gauge 74, as discussed in more detail below.
[0086] Referring now to FIGS. 13 and 14, with continued reference
to FIG. 10, the housing 106 includes multiple tabs 142 disposed
radially inward relative to the brackets 102 of the housing 106.
The tabs 142 engage the inner surface of the inner wall 68 as the
brackets 102 are slid over the retaining features 100 on the outer
surface of the inner wall 68. Thus, the inner wall 68 is positioned
between the brackets 102 and the tabs 142 when the pump and filter
assembly 104 is attached to the inner wall 68. The brackets 102 and
the tabs 142 are equally spaced around the perimeter of the pump
and filter assembly 104 so that the reservoir 36 can be rotated
relative to the pump and filter assembly 104 to reposition the
auxiliary pump 76.
[0087] Referring now to FIGS. 15 through 18, with continued
reference to FIG. 10, the auxiliary pump 76 includes the line
connection 128, a first tube 144, a second tube 146, a third tube
148. The line connection 128 is attached to the outer side of the
second tube 146. The first tube 144 and the second tube 146 extend
axially. The third tube extends horizontally and connects the first
tube 144 and the second tube 146. The upper ends of the first tube
144, the second tube 146, and the line connection 128 each include
line-engaging features 150, such as ridges, which engage fuel lines
to secure the fuel lines to the auxiliary pump 76. The auxiliary
pump 76 also includes bosses 152 that extend horizontally from the
outer sides of the first and second tubes 144, 146.
[0088] The bosses 152 are inserted into vertical slots 154 defined
in the supports 72 to mount the auxiliary pump 76 to the reservoir
36. As best shown in FIG. 16, the bosses 152 are radially offset
relative to one another to prevent the bosses 152 from sliding out
of the vertical slots 154 due to rotation of the auxiliary pump 76
about a radial axis of the auxiliary pump 76. Thus, the offset
bosses 152 are used to retain the auxiliary pump 76 in the supports
72.
[0089] As best shown in FIGS. 17 and 18, the inner surface of the
first tube 144 defines a first nozzle 156 and a first cylindrical
passage 158, and the inner surface of the second tube 146 defines a
second nozzle 160 and a second cylindrical passage 162. An orifice
164 provides fluid communication between the first tube 144, the
second tube 146, and the line connection 128. The orifice 164 is
disposed between the first nozzle 156 and the first cylindrical
passage 158 and between the second nozzle 160 and the second
cylindrical passage 162.
[0090] When fuel is not flowing through the auxiliary pump 76 or
when a vacuum is initially created within the auxiliary pump 76,
the seals 130 and the floats 132 engage the lower end of the
auxiliary pump 76 to prevent fuel from flowing through the lower
end of the auxiliary pump 76, as best shown in FIG. 17. As the
vacuum draws fuel through the upper end of the auxiliary pump 76,
the fuel forces the seals 130 and the floats 132 downward into the
prime boxes 84. This allows the fuel to enter the reservoir 36
through the lower end of the auxiliary pump 76, as best shown in
FIG. 18.
[0091] Referring now to FIGS. 19 and 20, the outer wall 66 of the
reservoir 36 includes retaining features 166, such as tabs,
disposed in one of the grooves 92 extending axially along the
length of the outer wall 66. The auxiliary filter 90 is inserted
between the retaining features 166, and the retaining features 166
engage the auxiliary filter 90 to create a snap fit that secures
the auxiliary filter 90 against the outer wall 66. The auxiliary
filter 90 may filter fuel drawn through the pickup line 88 by the
auxiliary pump 76. Alternatively, the auxiliary filter 90 may be
replaced with a simple inlet port (not shown) that does not filter
fuel as the auxiliary pump 76 draws the fuel through the pickup
line 88.
[0092] Referring now to FIGS. 21 through 23, the sender gauge 74
includes a boss or rod 168 disposed at the lower end of the sender
gauge 74, and legs 170 connecting the rod 168 to the card mount
120. As best shown in FIG. 21, the rod 168 extends horizontally and
the legs 170 extend axially when the sender gauge 74 is mounted
within the reservoir 36. The vertical slots 154 in the support 72
may be V-shaped and may be configured to create a snap fit between
the supports 72 and the rod 168. As best shown in FIG. 22, the ends
of the rod 168 are radially offset from one another to match the
radial offset between the vertical slots 154 in the supports 72.
This radial offset prevents the rod 168 from sliding out of the
vertical slots 154 due to rotation of the sender gauge 74.
[0093] As best shown in FIG. 23, the sender gauge 74 includes a
bracket 172 and a boss 174 that extend radially inward from the
card mount 120. When the sender gauge 74 is assembled to the inner
wall 68, the bracket 172 is placed over one of the first
subsections 136, and the boss 174 is inserted into the adjacent one
of the vertical slots 134. The bracket 172 is L-shaped and is
configured to wrap around the top edge of the inner wall 68 to
create a press fit between the sender gauge 74 and the inner wall
68. The flanges 140 at the edges of the first subsection 136 engage
the sides of the bracket 172, and the flanges 140 defining the
vertical slot 134 engage the sides of the boss 174. This engagement
aligns the sender gauge 74 relative to the inner wall 68.
[0094] Referring now to FIGS. 24 and 25, the flange 30 includes an
electrical connection 176. The control module may communicate with
the fuel pump module via the electrical connection 176. In this
manner, the control module may control operation of the main pump
38 and the check valve 42, and the control module may receive a
fuel level signal from the sender gauge 74. The rod sockets 64 are
equally spaced around the perimeter of the flange 30 to correspond
to the equal spacing between the rod sockets 60 in the reservoir 36
of FIG. 11. As indicated above, this equal spacing enables rotation
of the reservoir 36 relative to the flange 30 to satisfy packaging
requirements.
[0095] The foregoing description of the embodiments has been
provided for purposes of illustration and description. It is not
intended to be exhaustive or to limit the disclosure. Individual
elements or features of a particular embodiment are generally not
limited to that particular embodiment, but, where applicable, are
interchangeable and can be used in a selected embodiment, even if
not specifically shown or described. The same may also be varied in
many ways. Such variations are not to be regarded as a departure
from the disclosure, and all such modifications are intended to be
included within the scope of the disclosure.
* * * * *